Nonwoven female component for refastenable fastening device and method of making the same

ABSTRACT

A female component for a refastenable fastening device having an elastomeric adhesive backing and a multiplicity of fibrous elements extending from the backing. The female fastening component is formed by a method comprising the steps of: providing a first lamina comprising an elastomeric, pressure-sensitive adhesive film having a first adhesive surface and a second adhesive surface opposed to said first adhesive surface, a relaxed orientation and an elongated orientation; stretching said first lamina from said relaxed orientation to said elongated orientation; contacting a second lamina comprising a nonwoven web with said first surface of said first lamina in said elongated orientation, thereby directly joining said second lamina and said first lamina to form a laminate; and relaxing said first lamina such that said second lamina is shirred to form catching regions capable of entangling the hooks of a complementary male fastening component.

This is a continuation of application Ser. No. 08/254,814, filed on Jun.6, 1994, now abandoned.

FIELD OF THE INVENTION

The present invention relates to a female component for refastenablehook and loop type fastening devices and, more particularly, to alow-cost female component for a hook and loop type fastening device anda method for producing such a female fastening component.

BACKGROUND OF THE INVENTION

Refastenable fastening devices of the hook and loop type are currentlyused widely in a great number of situations. Such refastenable fasteningdevices have been particularly useful in clothing, disposable absorbentarticles, and the like. Such devices are used when it is desirable tocreate a refastenable bond between two or more articles or betweenseveral surfaces of the same article. In certain applications, theserefastenable fastening devices have replaced conventional buckles,zippers, buttons, snaps, tie fasteners, and sewing.

A popular type of mechanical fastener currently in wide use whichutilizes mechanical entanglement to create a refastenable bond is soldunder the trademark "VELCRO". VELCRO fastening devices are described ingreater detail in U.S. Pat. No. 2,717,437, U.S. Pat. No. 3,009,235, U.S.Pat. No. 3,266,113, U.S. Pat. No. 3,550,837, U.S. Pat. No. 4,169,303,and U.S. Pat. No. 4,984,339.

VELCRO fasteners utilize two components. A male component and a femalecomponent. The male and female components are often referred to as thehook and loop components, respectively. The male component contains aplurality of resilient, upstanding hook shaped elements. The femalecomponent of the fastening device generally consists of a fabriccontaining a plurality of upstanding loops on its surface. When the malecomponent and the loop component are pressed together in a face to facerelationship to close the fastening device, the hooks entangle the loopsforming a plurality of mechanical bonds between the individual hooks andloops. When these bonds have been created, the components will notgenerally disengage under normal conditions. This is because it is verydifficult to separate the components by attempting to disengage all thehooks at once. However, when a gradual peeling force is applied to thecomponents, disengagement can be easily effected. Under a peeling force,since the hooks are comprised of a resilient material, they will readilyopen to release the loops.

This type of fastening device has been found especially useful ondisposable articles such as disposable garments, disposable diapers,disposable packages, cartons, and the like. Such fastening devicesprovide a secure closing means. However, the use of existing fasteningdevices of this type on disposable articles has been limited due to thefact that such fastening devices are relatively costly. A major reasonthat such fastening devices are costly is that they have highmanufacturing costs. These high manufacturing costs are associated withboth the hook and loop components of these devices.

Conventional hook and loop components are typically formed by making afabric with a number of woven loops extending outwardly from a backing.The loops may be provided by weaving a base fabric containingsupplementary threads to form the loops, or by knitting the loops into afabric. In other hook and loop components, the loops may be formed bypleating or corrugating processes. The male components of such fasteningdevices are typically formed by subsequently cutting the loops. The cutloops serve as the hooks of the male component.

These processes generally produce costly hook and loop fasteningmaterials because they are relatively slow. The hook and loop componentsof such fastening devices are also usually made out of the samerelatively expensive material. This material is relatively expensivebecause the material used in the male component needs to be resilient sothat the hooks can disengage from the loop component when the device isopen.

Several attempts have been made to make alternative types of femalecomponents for fastening devices. However, such attempts have generallysuffered from a number of drawbacks.

U.S. Pat. No. 3,694,867 issued to Stumpf on Oct. 3, 1972, discloses a"separable clasp" having a female component that comprises a "high loft"nonwoven fabric and a backing layer of consolidated flexible adhesive.However, the loop component disclosed in the Stumpf patent is preparedby performing the steps of: (1) activating an open pattern adhesive inwhich the fibers are imbedded, (2) consolidating the adhesive into asubstantially continuous backing layer, and (3) simultaneously loopingportions of the fibers such that the fibers form individual loops thatextend outwardly from the backing. The female component disclosed inthis patent suffers from the drawback that it is made by processes thatinvolves mechanically manipulating fibers in the form of loops. Thus,the female components described therein do not appear to besignificantly less expensive to manufacture than conventional loopcomponents.

U.S. Pat. No. 4,761,318 issued to Ott, et al. on Aug. 2, 1988, disclosesa loop fastener that can contemporaneously be both formed and alsoattached to a substrate without the need for any additional steps suchas sewing or utilizing pressure sensitive adhesives to affix it to thesubstrate. However, the Ott loop fastener comprises a fibrous structurehaving a multiplicity of loops that is adhered to a layer ofthermoplastic resin. Thus, the process disclosed in this patent suffersfrom the drawback that heat must be applied to bond the fibrousstructure to the backing.

U.S. Pat. No. 3,708,833 issued to Ribich, et al. on Jan. 9, 1973,discloses a refastenable fastening device having a female component thatcomprises reticulated urethane foam secured to a backing layer. Thefemale component disclosed in the Ribich, et al. patent suffers from thedrawback that foams typically do not have enough openings for the hooksof conventional male components to penetrate. In addition, reticulatedfoam generally does not have sufficient strength to hold such hooks whenforces are applied to the fastening device. Further, manufacturingreticulated foam is a relatively expensive process.

U.S. Pat. No. 5,032,122 issued to Noel, et al. on Jul. 16, 1991,discloses a loop fastening material having a backing of orientablematerial and a multiplicity of fibrous elements extending from thebacking. The fibers are secured to the backing while the backing is in adimensionally unstable state. The backing is then caused to betransformed to its dimensionally stable state thereby shearing thefibrous elements to form the catching regions of the loop material.Although the Noel patent discloses an acceptable low cost loop fasteningmaterial, the search has continued for more economical loop fasteningmaterials and methods for producing such materials.

Thus, it is an object of the present invention to provide an improvedfastening device for disposable articles.

It is another object of the present invention to provide an improvedfemale component of a refastenable hook and loop type fastening device.

It is a further object of the present invention to provide a femalecomponent for a hook and loop type fastening device which may be formedby positioning a plurality of filaments on an elastomeric adhesivebacking without manipulating the fibers into the form of loops to form alow cost loop fastening material.

It is another object of the present invention to provide a femalecomponent for a fastening device that can be used with both commerciallyavailable male components having resilient individual hooks, as well asless expensive male components with more brittle hooks than thosecurrently in use.

It is a still further object of the present invention to provide a lowcost and improved method for producing a female component for a hook andloop type fastening device.

These and other objects of the present invention will be more readilyapparent when considered in reference to the following description andwhen taken in connection with the accompanying drawings.

SUMMARY OF THE INVENTION

The present invention provides a loop fastening material having anelastomeric adhesive backing and a multiplicity of fibrous elementsextending from the backing. The fibrous elements are formed by filamentspositioned on the backing when the backing is in an elongatedorientation. The filaments are preferably positioned on the backingessentially parallel to each other and essentially parallel orperpendicular to the path of response of the backing material. Thefilaments are preferably intermittently secured to each other at spaced,fixed regions so that the fixed regions define therebetween catchingregions. Thus, the fibrous elements are formed by shirring of thefilaments at the catching regions when the backing material is returnedto its relaxed orientation.

The loop fastening material is formed by a method comprising the stepsof:

(a) providing a first lamina comprising an elastomeric,pressure-sensitive adhesive film having a first adhesive surface and asecond adhesive surface opposed to said first adhesive surface, arelaxed orientation and an elongated orientation;

(b) stretching said first lamina from said relaxed orientation to saidelongated orientation;

(c) contacting a second lamina comprising a nonwoven web with said firstsurface of said first lamina in said elongated orientation, therebydirectly joining said second lamina and said first lamina to form alaminate; and

(d) relaxing said first lamina such that said second lamina is shirredto form catching regions capable of entangling the hooks of acomplementary male fastening component.

The present invention also relates to a fastening device having a hookfastening material and a loop fastening material. The loop fasteningmaterial comprises the improved loop fastening material of the presentinvention. The hook fastening material comprises any of the well knownhook fastening materials as are known in the art and which have a baseand a number of engaging elements extending from the base. The loopfastening material and the complimentary hook fastening material providea secure closing means that will resist shear stress and peel forcesencountered during use.

The present invention also relates to disposable articles and moreparticularly to a disposable diaper having such an improved fasteningdevice.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the filaments and the backing used toform the present invention prior to the filaments being positioned orlaid down on the backing.

FIG. 2 is a perspective view of the female component of the presentinvention when the backing is in its elongated orientation.

FIG. 3 is a perspective view of the female component of the presentinvention when the backing is in its relaxed orientation.

FIG. 4 is a perspective view of a fastening device according to thepresent invention.

FIG. 5 is a greatly enlarged side view of the fibrous elements of thefemale component of the present invention.

FIG. 6 is a greatly enlarged side view of an alternative tri-laminateembodiment of the present invention.

FIG. 7 is a perspective view of a disposable diaper that includes thefastening device of the present invention.

FIG. 8 is a perspective view of a disposable diaper that includes thefastening device of the present invention.

FIG. 9 is a schematic side view of a process for making the femalecomponent of the present invention.

FIG. 10 is a schematic top view of a part of the process for making thefemale component of the present invention.

FIG. 11 is a schematic top view of an alternative embodiment of theprocess for making the female component of the present invention.

FIG. 12 is a schematic top view of an alternative embodiment of theprocess for making the female component of the present invention.

FIG. 13 is an isometric view of a part of the process for making thefemale component of the present invention.

FIG. 14 is a schematic side view of one embodiment of the process formaking the tri-laminate embodiment of the present invention.

FIG. 15 is a schematic side view of an alternative embodiment of theprocess for making the tri-laminate embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION Overall Characteristics of theRefastenable Fastening Device

A preferred embodiment of the refastenable fastening device of thepresent invention, fastening device 20, is shown in FIG. 4. Thefastening device 20 comprises a nonwoven female component 22 and acomplementary hook fastening component 24.

The female portion of the device, more specifically, the nonwoven femalecomponent (or simply "female component") 22 receives and engages thehooks 28 of the male component. The female component 22 shown in FIGS. 3and 4 comprises at least one nonwoven web 30 secured to a backing 34. Asshown in FIG. 1, the nonwoven web 30 has an outwardly-facing surface 21and an inwardly-facing surface 23 opposed to the outwardly-facingsurface 21. The nonwoven web 30 comprises a plurality of filaments (orfibers) 36 that entangle the hooks 28 of the male component 24. Thebacking has a first surface 31 and a second surface 33 opposed to thefirst surface 31, and preferably comprises an elastomeric adhesive.

The male portion of the device, more specifically, the hook fasteningcomponent (or simply "hook component") 24, comprises a base 26 having afirst surface 27 and a second surface 29. The base 26 comprises aplurality of upstanding engaging elements, or "hooks" 28, extending fromthe first surface 27. The term "hook" is nonlimiting in the sense thatthe engaging elements may be in any shape known in the art so long asthey are adapted to engage a complimentary loop fastening component orthe female component 22 of the present invention. The hooks 28 generallyhave heads 38 (or engaging means) which are disposed on top of theshanks, or stems 40, that extend from the first surface 27 of the malecomponent 24.

The fastening device 20 of the present invention functions in thefollowing manner. The fastening device 20 is closed when the femalecomponent 22 and the male component 24 are pressed face-to-face againsteach other. When this happens, the hooks 28 are entangled by the fibers36 of the nonwoven web 30. The nonwoven web 30 provides space for thehooks, particularly, the heads 38 of the hooks to occupy when thefastening device 20 is closed. The backing 34 provides a supportingfoundation for the nonwoven web 30. With the hooks 28 mechanicallyentangled by, or "hooked", onto the fibers 36 (shown in the portion ofthe fastening device 20 to the right side in FIG. 4), the connectionbetween the components resists the forces that may be exerted on thefastening device 20.

The fastening device 20 is opened by peeling the male component 24 awayfrom the female component 22 (or by peeling the female component 22 awayfrom the male component 24). If the male component 24 has resilienthooks, the peeling action may cause the hooks to be bent so that theyare disengaged from entanglement with the fibers 36 of the nonwoven web30. In other cases (particularly if the hooks 28 are relativelyinflexible), the hooks 28 may be separated by breaking the fibers 36 ofthe female component 22. In either case, the hooks 28 are disengaged andthe male component 24 is completely detached from the female component22. The fastening device 20 is then capable of being refastened in themanner described above.

The Female Fastening Component

The term "nonwoven female component", as used herein refers to a femalecomponent for a refastenable fastening device that comprises a nonwovenweb joined to a backing. (The nonwoven female component may also bereferred to as a loop fastening material or simply, a loop fastener.)The term "nonwoven web" refers to fabrics made of fibers held togetherby interlocking or inter-fiber bonding which are not woven, knitted,felted, or the like. However, the nonwoven web referred to herein maycomprise fibers that are initially substantially unbonded which aresubsequently bonded to each other.

FIG. 1 shows the backing 34 and the nonwoven web 30 used to form thefemale component 22 prior to their association. The backing 34,preferably an elastomeric adhesive, is shown in its elongatedorientation (stretched in a direction parallel to the line designatedA--A). As used herein, the term "elastomeric" refers to materials thatextend in at least one direction when a force is applied and return toapproximately their original dimensions after the force is released. Thenonwoven web 30, as shown in FIG. 1, preferably comprises a multiplicityof filaments 36 that are joined with each other by inter-fiber bonds 32prior to being associated with the backing 34. As used herein, the term"joined" encompasses configurations whereby an element is directlysecured to another element and configurations whereby an element isindirectly secured to another element by affixing an element tointermediate member(s) which in turn are affixed to another element. Theterm "inter-fiber bonds" refers to bonds that join one or more filamentsto one or more other filaments.

FIG. 2 shows a preferred embodiment of the female component 22 where thebacking 34 is in its elongated orientation after the nonwoven web 30 hasbeen positioned on and joined to the first surface 31 of the backing 34.Preferably, the filaments 36 of the nonwoven web 30 are alignedessentially parallel to each other and essentially perpendicular to thepath of response of the backing 34. ("Essentially perpendicular" is usedherein to indicate that the filaments 36 need not extend absolutelyperpendicular to the path of response so long as the majority of thefilaments 36 extend perpendicularly to or a small deviation offperpendicularly to the path of response. As used herein, the term "pathof response" refers to the direction in which an elastomeric material inan elongated orientation will respond when the forces acting to elongatethe elastomeric material are removed. Further, the filaments 36 of thenonwoven web 30 are preferably in an untensioned state when they arejoined to the elongated backing 34.) This helps to ensure that thefilaments 36 will become "shirred" when the backing 34 contracts to itsrelaxed orientation (shown in FIG. 3). The term "shirred" as usedherein, refers to the gathering of the filaments 36 of the nonwoven web30 caused by the contraction of the backing 34 from its elongatedorientation to its relaxed orientation such that portions of thefilaments 36 that are not secured to the backing 34 or other filaments36 bend away from the first surface 31 of the backing 34. The shirredfilaments 36 form unsecured catching regions 37 (loops) capable ofentangling the hooks 28 of a complementary male fastening component 24.

FIG. 3 shows a preferred embodiment of the present invention after thenonwoven web 30 and the backing 34 have been joined and after the forcesacting to elongate the backing 34 have been removed such that thebacking 34 has contracted to its relaxed orientation. The shirredfilaments 36 form a multiplicity of fibrous elements 35 extendingoutwardly from the first surface 31 of the backing 34. Each of thefibrous elements 35 comprises a pair of fixed regions 42 (joined to thebacking 34) and an unsecured catching region 37 disposed between thepair of fixed regions 42. The catching regions 37 are capable ofsecurely engaging the hooks of a complementary hook fastening componentto provide a fastening device 20, as is shown in FIG. 4.

1. The Nonwoven Web

The fibrous elements 35 of the present invention are preferably formedfrom filaments 36 positioned on and secured to the backing 34. As usedherein, the term "filament" defines a member having a high ratio oflength to diameter or width. (FIG. 5 shows a portion of the femalefastening component 22 greatly enlarged to show the filaments 36 indetail.) Thus, a filament may be a fiber, a thread, a strand, a yam orany other member or combination of these members, including filamentsthat are preattached together in nonwoven webs, as are known in the art.Suitable materials for such filaments 36 include natural fibers such ascotton or wool; synthetic fibers of nylon, polyamides, polyesters, orpolyolefins; spun yarns; polyethylene fibers; polypropylene fibers;nylon fibers, non-woven webs; or any other material or combination ofmaterials known in the art and suitable for use herein.

The filaments 36 may be manufactured using a number of manufacturingtechniques including those such that the filaments are spun, blown, orthe like. Preferably, each filament 36 comprises a polypropylene fibersof between about 2 and about 15 denier. The individual filaments 36 arepreferably comprised in a nonwoven web 30 having a basis weight ofbetween about 10 g/yd2 and about 40 g/yd2 (about 12 g/m2 to about 48g/m2), more preferably between about 15 g/yd2 and about 25 g/yd2 (about18 g/m2 and about 30 g/m2). The nonwoven web 30 may comprise filaments36 having similar or different deniers and lengths. Further, thenonwoven web 30 may comprise a mixture of filaments 36 comprisingdifferent materials. Some nonwoven webs comprising suitable filamentsinclude the carded polypropylene nonwoven web manufactured by theVeratec Nonwoven Group of the International Paper Company, of Walpole,Mass. under the trade name P-11, the spunbonded polypropylene nonwovenweb P-9, and the carded polypropylene nonwoven web P-8. Other suitablenonwoven webs comprising suitable filaments include COROVON spunbondedpolypropylene manufactured by Corovin GmbH of Germany, and CELESTRAmanufactured by the James River Corporation.

The lengths of the filaments 36 in the nonwoven web 30 depend upon thetype of process used to make the nonwoven web 30. For instance, if acarded nonwoven web is used, the filaments 36 that comprise such a webcan have lengths that range from about 0.5 inches to about 5 inches(from about 1 cm. to about 13 cm.). In preferred carded nonwoven webs,the filaments are between about 1 inch and about 3 inches (between about2.5 cm. and about 8 cm.) long. Alternatively, if a spunbonded nonwovenweb is used, the filaments 36 of such a web will typically be continuouslength. (As used herein, the term "continuous" refers to relatively longfilaments that run the entire length of the nonwoven web.)

A preferred filament 36 has a length to make at least one completefibrous element 35. Thus, for example, the filament 36 may only have apair of fixed regions 42 positioned adjacent its ends so that thefibrous element 35 is formed of a whole filament 36. More preferably,the filament 36 has a number of fixed regions 42 positioned along itslength to form a plurality of fibrous elements 35 along each filament36. If the filaments 36 are short, or staple, complete fibrous elements35 having two fixed regions 42 and catching regions 37 may not beformed. The resulting incomplete fibrous elements 35 may not be able tosecurely engage the hooks 28 of a complementary hook fastening material24. Thus, the ability of the nonwoven female component 22 to provide asecure closure may be diminished.

The amount of inter-fiber bonding between the filaments 36 of thenonwoven web 30 is also an important factor relevant to the ability ofthe female component 22 of the present invention to entangle thecomplementary hook fastening component 24. An excessive number of bondsites created between the filaments 36 in the nonwoven web 30 will tendto interfere with the entry of hooks 28 into the nonwoven web 30, thusreducing the shear strength of the fastening device. (In general, thestrength of the fastening device will be increased as more hooks areable to enter and engage the nonwoven web.) Alternatively, too fewinter-fiber bonds 32 may increase the number of filaments 36 havingloose (unbonded) ends, thus reducing the female component's 22 abilityto entangle the hooks 28 of the complementary hook fastening component24.

In a preferred embodiment of the present invention, the total plan viewarea of the inter-fiber bonds 32 is between about 1 percent and about 35percent of the total area of the nonwoven web 30. More particularly, thetotal plan view area of the inter-fiber bonds is between about 5 percentand about 25 percent of the total area of the nonwoven web. Thepercentage of inter-fiber bonding is preferably measured by examining arepresentative sample of the nonwoven web under a microscope. The sampleis viewed from directly above the outwardly-facing surface 21 of thenonwoven web 30. The plan view area of each inter-fiber bond 32 ismeasured. The sum of the areas of the bonds is divided by the area ofthe sample. The result is the percentage area occupied by theinter-fiber bonds.

The pattern of the inter-fiber bonds within the nonwoven web is anotherimportant factor relating to the strength and overall efficacy of thefemale component. The inter-fiber bonds 32 may be continuous lines orintermittent areas of bonding. Preferably, the inter-fiber bonds 32 aresufficiently close together that the filaments 36 of the nonwoven web 30have relatively few unbonded loose ends. Thus, the distance betweeninter-fiber bonds 32 is preferably less than the average length of thefilaments 36 in the nonwoven web 30, more preferably, less than aboutone-half the average length of the filaments 36 in the nonwoven web 30.

In a preferred embodiment of the present invention, the inter-fiberbonds 32 are arranged in a regular pattern. As used herein, the term"regular" refers to bond patterns that are generally similar throughoutthe area of the nonwoven web 30 when viewed from directly above theoutwardly-facing surface 21 of the nonwoven web 30. Suitable inter-fiberbonding patterns include a series of straight or curved lines, orarrangements of inter-fiber bonds 32 that form grids defining differentgeometrical shapes such as squares, rectangles, hexagons, diamonds, andcircles. Such regular patterns will provide the female component 22 withrelatively uniform holding characteristics.

One bonding pattern that has been found to work especially well in thefemale component 22 of the present invention is the intermittentdiamond-shaped pattern shown in FIGS. 1 and 2. The "diamonds" in thediamond-shaped pattern comprise a number of intermittent inter-fiberbonds 32 regularly arranged in lines that define the edges of generallysquare shaped regions. (A preferred arrangement of the inter-fiber bonds32 of the nonwoven web 30 before the filaments 36 become shirred isshown on the left side of FIG. 2. A preferred arrangement of theinter-fiber bonds 32 of the nonwoven web 30 after the filaments 36 havebecome shirred is shown on the left side of FIG. 4.). The pattern isrotated approximately 45 degrees to give the appearance of diamonds.Preferably, the dimensions of the pattern should be such that thedistance between the inter-fiber bonds 32, in at least some portion ofthe area between the sides of the diamond-shaped areas, is greater thanthe projected plan view dimensions of the hooks 28 of the complementarymale component 24. (Plan view dimensions of complementary malecomponents are discussed in greater detail below.) Nonlimiting examplesof diamond-shaped bonding patterns suitable for use in female component22 of the present invention include patterns having sides that measurebetween about 1/2 inch×1/2 inch (about 1.3 cm.×1.3 cm.) and about 1/8in×1/8 in. (about 0.3 cm.×0.3 cm.), more preferably between about 1/4inch×1/4 inch (about 0.6 cm.×0.6 cm.) and about 3/8 inch×3/8 inch (about1 cm.×1 cm.), and most preferably about 1/4 inch×1/4 inch (about 0.6cm.×0.6 cm.). A suitable nonwoven web 30 comprising inter-fiber bonds 32arranged in a diamond-shaped pattern is available from the VeratecNonwoven Group of the International Paper Company, of Walpole, Mass.under the trade name P-11.

The inter-fiber bonds 32 may be produced by any method that is known inthe art. In a preferred embodiment, the inter-fiber bonds 32 areproduced by passing a nonwoven web 30 through a pair of rollers thathave been heated close to the melting point of the filaments 36comprised in the nonwoven web 30. One of the rollers preferably has asmooth surface; the complementary roller has a pattern of pins extendingfrom its surface in the diamond-shaped pattern described above. When thenonwoven web 30 passes between the rollers, the heat and pressure of therollers causes distinct regions of the filaments 36 to melt producinginter-fiber bonds 32 in the preferred diamond-shaped pattern.

The nonwoven web 30 is preferably positioned on and joined with thebacking 34 while the backing 34 is in an elongated orientation and whilethe filaments 36 are in an untensioned condition. While the filaments 36could conceivably be positioned on the backing 34 in a tensioned orunstable state, such is not preferred to provide maximum shirring of thefilaments 36. Further, while the backing 34 could be in a relaxedorientation when the filaments 36 are positioned on the backing 34, thisis not preferred because in causing the backing 34 to become elongated,enough filaments 36 may be dislocated, disarranged, skewed or bonded tothe backing 34 such that the fibrous elements 35 would not be aseffective in engaging the hook fastening component.

The configuration in which the filaments 36 are positioned or laid downon the backing 34 determines the size and the ability of the loopfastening component 22 to provide an effective fastening device. Whilethe filaments 36 may be randomly positioned on the backing 34 such thatthe filaments 36 overlap or extend in many different directions, it hasbeen found that the filaments 36 should preferably be positioned asparallel with each other as possible to provide fibrous elements 35configured in a uniform direction. In addition, while the filaments 36may be positioned lengthwise on the backing 34 in any direction, inorder to take advantage of the maximum shirring effect of the backing 34to form fibrous elements 35 of maximum height, the filaments 36 arepreferably positioned on the backing 34 in a direction essentiallyperpendicular to the path of response of the backing 34. (It has beenfound, however, that filaments 36 positioned essentially parallel to thepath of response also provide suitable entangling ability.) Thefilaments 36 may be positioned or laid down on the backing 34 by anymethod or means that is known in the art.

2. The Backing

The backing 34 of the present invention is that part of the femalefastening component 22 to which the nonwoven web 30 is secured. Thebacking 34 is preferably comprised of an elastomeric, pressure sensitiveadhesive, so that it may be readily joined to the nonwoven web 30 toform the nonwoven female component 22. As used herein, the term"elastomeric" refers to materials that extend in at least one directionwhen a force is applied and return to approximately their originaldimensions after the force is removed. Thus, elastomeric materials havean elongated orientation (when force is applied) and a relaxedorientation (when force removed). The term "adhesive" refers tomaterials which are capable of bonding to another material by sticking,or adhering, to the surface of the other material. A "pressure sensitiveadhesive" is an adhesive that is responsive to pressure, i.e., iscapable of adhering under the influence of pressure alone.

The elastomeric adhesive comprising the backing 34 of the presentinvention may take on a number of different configurations. For example,the backing 34 may comprise a thin film having a uniform or varyingthickness, slits, holes, deformations or the like; a laminate of two ormore films; a web of elastomeric adhesive; a single or multiple strandsof elastomeric adhesive; discrete regions of elastomeric adhesive formedin random or regular patterns; or any combination of the above. In onepreferred embodiment, the backing 34 comprises an elastomeric adhesivethat has been extruded in the form of a thin film of about 0.03 mm. toabout 1.0 mm. (about 0.001 in. to about 0.04 in.). In a particularlypreferred embodiment, the elastomeric film has a thickness of betweenabout 0.025 mm. to about 0.38 mm (about 0.001 in. to about 0.015 in.).

The elastomeric adhesive selected for the backing 34 may comprise any ofa number of different elastomeric adhesives as are known in the art. Theelastomeric adhesive preferably has an elastic modulus between about 1and about 30 PSI and more preferably between about 5 and about 15 PSI.(The elastic modulus calculation is preferably determined on the straininterval of about 50% to about 150% elongation of any convenient gagelength using the original cross sectional area of the sample prior tostraining the sample to determine the elastic modulus.) Further, theelastomeric adhesive should be capable of elongation from about 500 toabout 1000 percent in at least one direction without rupture. Morepreferably, the elastomeric adhesive should be capable of between about500 percent and about 1000 percent elongation without rupture, notexhibit excessive necking or thinning when elongated, or exhibitexcessive hysteresis or delamination upon elongation.

Other characteristics that help define suitable elastomeric adhesivesrelate to the process in which the present invention is made. Asdescribed below, the elastomeric adhesive preferably forms a film thatis stretched prior to the application of the nonwoven to the elastomericadhesive backing. One preferred method of inducing the stretch is toadhere a portion of the elastomeric adhesive film to tentering beltsthat diverge to stretch the film. The overlap between the film and thetentering belts forms a "lap joint". (The term "diverge" is used hereinto mean move apart. The term "lap joint" refers to the area where twooverlapping materials are joined together.) Preferably, the tensilestrength of the film should be less than the lap shear bond strengthbetween the film and the tentering belts. (As used herein, the term"tensile strength" refers to the pulling stress required to break agiven specimen. The term "lap shear bond strength" refers to the forceneeded to disrupt a lap joint, wherein the force applied is essentiallyparallel to the surface which adjoins the elastomeric adhesive film andthe tentering belts.) Thus, as the tentering belts diverge and stretchthe film, the bond between the film and the tentering belts remains intact.

A pressure sensitive elastomeric adhesive marketed by the FindleyAdhesive Corporation of Wauwatosa, Wis. under the trade name 198-338,has been found to be particularly well suited for this purpose. However,other suitable elastomeric materials include H2206 and HS2206, each ofwhich is available from the Findley Adhesive Corporation.

Alternative Embodiments

FIG. 6 shows an alternative embodiment of the female component 22 of thepresent invention comprising a second lamina 80 joined to the secondsurface 33 of the elastomeric adhesive backing 34 to form a tri-laminate85. Joining a second lamina 80 to the elastomeric adhesive backing 34provides the female fastening component with additional advantages. Forinstance, the tri-laminate material 85 may be incorporated into adisposable absorbent article, such as a diaper as an elastomericwaistband capable of engaging the hooks of a complementary malefastening component. Further, the tri-laminate 85 provides anelastomeric female fastening component 22 capable of engaging the hooks28 of a complementary male fastening component 24 on two opposingsurfaces.

In an especially preferred alternative embodiment of the presentinvention, the second lamina 80 comprises a nonwoven web such as thenonwoven web 30 described above with respect to the female fasteningcomponent 22. However, a suitable lamina may be manufactured from a widerange of materials, including plastic films; woven webs of naturalfibers (e.g. wood or cotton), synthetic fibers (e.g. polyester orpolypropylene), or a combination of natural and synthetic fibers; foams;or natural or synthetic rubber.

The second lamina 80 may be joined to the elastomeric adhesive backing34 in the manner described with respect to the nonwoven web 30 or anyother method as is known in the art. Further, the second lamina 80 maybe joined to the backing 34 contemporaneously with the nonwoven web 30when the backing 34 is in an elongated orientation or at any other timeafter the adhesive backing 34 is formed. In a preferred embodiment,however, the lamina 80 is joined to the backing 34 after the nonwovenweb 30 has been joined to the backing 34 and after the backing 34 hasbeen at least partially relaxed. (An elastomeric material in anelongated orientation is "partially relaxed" when the forces stretchingthe elastomeric material are reduced, allowing the material to contractbut not completely relax. Thus, an elastomeric material in a partiallyrelaxed condition is still capable of contracting further to its relaxedorientation after the forces are completely removed.) Joining the secondlamina 80 after the backing 34 has been at least partially relaxedensures that the fibrous elements 35 of the nonwoven web 30 will remainshirred when the female fastening component 22 is stretched. This isbecause the second lamina 80 will become fully extended to its elasticlimit before the nonwoven web 30, thus maintaining at least someshirting in the filaments 36 of the nonwoven web 30. Thus, anelastomeric nonwoven female component 22 is provided that will maintainits ability to entangle the hooks 28 of a complementary male fasteningcomponent 24 even after the female component 22 has been stretched to apoint where the second lamina 80 is fully extended. (If the secondlamina 80 is joined to the backing 34 when the backing 34 is in itsfully relaxed orientation, the female component 22 will lose itselastomeric qualities. Thus, such an embodiment is not preferred wherethe female component must be capable of stretching.)

The Complementary Male Component

The term "male component", as used herein, is used to designate theportion of the fastening device 20 having engaging elements, such ashooks 28. The male components 24 used with the nonwoven female component22 of the present invention can be conventional, commercially availablehook materials. The male component 24, however, is not limited toconventional materials with flexible, resilient hooks 28. Suitable malecomponents can have less expensive, relatively inflexible, more brittlehooks. Further, the engaging elements may have any shape known in theart such as hooks, "T's", mushrooms, or any other shape. One suitablemale component 24 may comprise a number of shaped engaging elementsprojecting from a woven backing such as the commercially availablematerial designated "SCOTCHMATE" brand No. FJ3402 available fromMinnesota Mining and Manufacturing Company, St. Paul, Minn. A preferredmale component is described in U.S. Pat. No. 4,846,815 entitled"Disposable Diaper Having An Improved Fastening Device" which issued toC. L. Scripps on Jul. 11, 1989. Other particularly preferred malecomponents and methods for making the same are the prongs described inU.S. Pat. No. 5,058,247 entitled "Mechanical Fastening Prong" issued toThomas et al. on Oct. 22, 1991; U.S. Pat. No. 5,116,563 entitled"Process for Producing a Mechanical Fastener" issued to Thomas et al. onMay 26, 1992; U.S. Pat. No. 5,180,534 entitled "Process of ManufacturingA Refastenable Mechanical Fastening System", which issued to Thomas, etal. on Jan. 19, 1993; and U.S. Pat. No. 5,230,851 entitled "Process ofManufacturing a Refastenable Fastening System" issued to Thomas on Jul.27, 1993. Each of these patents are hereby incorporated by referenceherein.

The male component 24 may be manufactured from a wide range ofmaterials. Such suitable materials include, but are not limited to,nylon, polyester, polypropylene, or any combination of these or othermaterials.

Examples Of Uses Of The Refastenable Fastening Device

The refastenable fastening device of the present invention is especiallyuseful as a fastening device for disposable absorbent articles. The term"disposable absorbent article", as used herein, refers to articles whichabsorb and contain body exudates. More particularly, the term refers toarticles which are placed against or in proximity to the body of thewearer to absorb and contain the various exudates discharged from thebody. The term "disposable" means that such articles are intended to bediscarded after a single use (i.e., they are not intended to belaundered or otherwise be used). Examples of disposable absorbentarticles include diapers, incontinence garments, sanitary napkins,bandages, and the like.

FIGS. 7 and 8 show an exemplary disposable diaper 50 comprising afastening system 72 including the nonwoven female fastening component 22of the present invention. The diaper 50 preferably comprises a bodyportion 51 and two waist regions, a first waist region 56, and a secondwaist region 58. The body portion 51 preferably comprises a liquidpervious topsheet 64, a liquid impervious backsheet 68, and an absorbentcore 66.

As shown in FIG. 7, the fastening system 72 of the diaper 50 comprisesthe female fastening component 22 of the present invention, among otherelements. The fastening system 72 may take on a number of configurationsand constructions. In one preferred embodiment, the first fasteningelement 72a comprises a male component 24. The male component 24provides hooks 28 that extend from the tab 74 disposed in the secondwaist region 58. The nonwoven female component 22 of the presentinvention comprises the second fastening element 72b disposed in thefirst waist region 56. However, the positions of the components of thefastening device 20 of the present invention could be reversed so thatthe first fastening element 72a comprises the nonwoven female component22 and the second fastening element 72b comprises the male component 24.

In an especially preferred embodiment of the disposable diaper 50, thefilaments 36 in the nonwoven web 30 of the female component 22 arealigned in a single direction. The female component 22 is oriented sothat the filaments 36 in the nonwoven web 30 extend essentially parallelto the longitudinal edges 60 of the diaper 50. This orientation alignsthe filaments 36 generally perpendicular to the direction of shearforces applied to the fastening device 20 during use. In thisconfiguration the filaments 36 provide the maximum peel and shear forceresistance.

Several examples of well known diaper configurations to which thepresent invention can be readily adapted are described in U.S. Pat. Nos.5,151,092 and 5,221,274 both entitled "Absorbent Article With DynamicElastic Waist Feature Having A Predisposed Flexural Hinge", issued toKenneth B. Buell, et al. on Sep. 29, 1992 and Jun. 22, 1993,respectively; co-pending U.S. patent application Ser. No. 08/155,048entitled "Absorbent Article With Multi-Directional Extensible SidePanels", filed Nov. 19, 1993; and co-pending U.S. patent applicationSer. No. 08/203,456 entitled "Absorbent Article With Multiple ZoneStructural Elastic-Like Film Web Extensible Waist Feature" filed on Feb.28, 1994. Each of the above mentioned patents and co-pending patentapplications are hereby incorporated by reference herein. It should beunderstood, however, that the fastening device of the present inventionis not limited to use with any specific diaper structure orconfiguration.

The female fastening component 22 of the present invention may also beused to provide an inexpensive waistband, or any other elastomericelement (or a portion thereof) of an absorbent article, capable ofengaging the hooks 28 of a complementary male fastening component 24.(As used herein, the term "waistband" refers to that portion of anabsorbent article that partially or wholly encircles the waist of thewearer.) FIG. 8 shows a diaper 50 having a waistband 62 comprising thefemale fastening component 22 of the present invention. Further examplesof diapers suitable for use with the present invention are described inU.S. Pat. No. 4,699,622 entitled "Disposable Diaper Having An ImprovedSide Closure" which issued to J. W. Toussant, et al. on Oct. 13, 1987;U.S. Pat. No. 5,019,065 entitled "Disposable Absorbent Article WithCombination Mechanical and Adhesive Tape Fastener System", issued toScripps on May 28, 1991; and U.S. Pat. No. 5,242,436 entitled "AbsorbentArticle With Fastening System Providing Dynamic Elasticized WaistbandFit", issued to Well et al., on Sep. 7, 1993; each of which is herebyincorporated by reference herein.

Method of Making the Female Fastening Component

The female fastening component 22 of the present invention is made bycontacting a nonwoven web comprising inter-fiber bonds with anelastomeric, pressure sensitive adhesive film. The adhesive film isformed and elongated in at least the cross machine direction before itis brought in contact with the nonwoven web. When the adhesive film andthe nonwoven web are brought into contact with each other, they arejoined to form a laminate comprising the nonwoven web and an elastomericadhesive backing. The laminate is then contracted such that regions ofthe nonwoven web become shirred and thus capable of entangling the hooksof a complementary male fastening component.

The following is a detailed description of the process for making thefemale fastening component 22 of the present invention. Although thedescription refers to the elastomeric adhesive backing as an "adhesivefilm", this terminology should not be construed to limit the scope ofthe invention. As mentioned above, the adhesive backing 34 may take on anumber of different configurations including films, laminates, webs,strands, or the like.

The female component 22 of the present invention may be produced on theillustrated apparatus 110, as shown in FIG. 9. The apparatus 110comprises two separate process modules, process module 111 for theelastomeric adhesive backing 34 (or "adhesive film"), and process module112 for the nonwoven web 30. The process module 111 comprises anextrusion head 116 and a release surface upon which the extrudedadhesive is formed, such as the forming belt 117, to form theelastomeric adhesive backing film 34. (In an alternative embodiment, theelastomeric adhesive backing could be pre-formed and supplied to theline from a roll. This would eliminate the extrusion head 116 and theforming belt 117.)

Examining process module 111 in greater detail, the extrusion head 116has a slot through which the molten elastic adhesive of the adhesivefilm 34 is extruded to form a thin film of about 0.03 to about 1.0millimeters (about 0.001 in. to about 0.04 in.) in thickness, and of anydesired width, onto the forming belt 117. An adhesive film 34 having athickness of about 0.025 to about 0.38 millimeters (0.001-0.015 inches)is particularly preferred. Generally a thicker adhesive film 34 ispreferred as the thickness and stiffness of the nonwoven web 30increases. It will be apparent to one skilled in the art that increasingthe thickness of the adhesive film 34 will generally provide aproportional increase in the ultimate strength of the female fasteningcomponent 22. An adhesive film 34 of about 8.4 g/cm2 has been found tobe suitable.

The extrusion head 116 extrudes the molten adhesive onto the formingbelt 117 which cools the molten adhesive into an adhesive film 34suitable for processing and transports the adhesive film 34 to thetentering belts 135. A roll may be utilized in conjunction with the belt117 to provide additional cooling and a nip for compression of theadhesive film 34. Further, the adhesive film 34 may be separated fromthe forming belt 117 by a doctor blade (not shown).

After being removed from the forming belt 117, the application roll 131guides spaced apart regions of the adhesive film 34 onto the surface ofthe tentering belts 135. (As used herein, the term "spaced apart" refersto regions of the adhesive film 34 that are spaced apart in the crossmachine direction form each other.) The adhesive nature of the adhesivefilm 34 permits the adhesive film 34 to be secured to the tenteringbelts 135 without any additional securement means, as are generally usedin the art. Preferably, only about 1/4 inch to about 3/4 inch of theedges of the adhesive film 34 should be secured to the working surfaceof each tentering belt 135. (It should be noted, however, that thetentering belts could be designed such that a vacuum assists in holdingthe film in contact with the tentering belts.) The spaced apart regionsof the adhesive film 34 are adhered to the working surfaces of thetentering belts 135 forming continuous lap joints. (As used herein, theterm "continuous" means relatively unbroken or without interruption.)The continuous nature of the lap joint helps to ensure that the adhesivefilm 34 will be more evenly stretched than films that are elongated bystretching means comprising discrete mechanical clamping devices.

The tentering belts 135 are spaced apart in the cross machine directionand diverge as they move in the machine direction. The tentering belts135 preferably comprise a substantially flat working surface to whichthe adhesive film 34 is adhered, and members that help provide positivecontrol of the belts in both the machine and the cross machinedirections. The working surface of each tentering belt 135 is preferablycomprised of any material, such as TEFLON, to which the adhesive film 34will adhere sufficiently in shear to stretch the adhesive film 34, andfrom which the adhesive film 34 can peeled off without damaging theadhesive film 34 when it is removed. One belt with a suitable workingsurface is available from F. M. Sheppard & Co. of Erlanger, Ky., and issold as Belt Style No. 3W11-2A.

Each tentering belt 135 travels about a pair of pulleys. As shown inFIG. 13, belts 140 and 142 travel about pulleys 141a and 142b. Pulley141a defines the converging end 146 of the belts 140 and 142 whilepulley 141b defines the diverging end 144 of the belts. In one preferredembodiment, the pulleys 141a and 141b comprise V shaped grooves and thetentering belts 140 and 142 comprise V shaped extensions that ride inthe complementary V shaped grooves of the pulleys 141a and 141b, toprovide machine direction control of the belt in the cross machinedirection.

The tentering belts 135 may be driven by any driving means well known inthe art and are preferably not driven by the adhesive film 34. In onepreferred embodiment, each tentering belt 135 comprises teeth andgrooves that coact with the complementary driving means to provide crossmachine directional control of the belt as it is driven forwardly.

One embodiment of the present invention, as shown in FIG. 10, comprisestwo tentering belts 135, a first belt 140 and a second belt 142. A firstregion 159 of the second surface 33 of the adhesive film 34 is adheredto the first belt 140, and a second region 160 of the second surface 33of the adhesive film 34 is adhered to the second belt 142. The firstbelt 140 and the second belt 142 diverge as they move in the machinedirection, stretching the adhesive film 34 in the cross machinedirection. (The cross machine direction is denoted by the arrow C inFIG. 10.) This configuration is preferred when it is desired that theadhesive film 34 be evenly stretched. (Alternative embodimentscomprising more than two tentering belts are discussed below.)

As shown in FIG. 9, the nonwoven web 30 is taken from the unwind roll126 and preferably passes through the S-wrap tensioning roll 128 toprovide for proper tensioning and to prevent puckering or bunching ofthe nonwoven web 30. Guide roll 130 guides the nonwoven web 30 into thenip between the combining rolls 124. If necessary, a tracking system(not shown) as is commonly utilized and known in the art, may beemployed in the process module 112 to optimally track and adjust thewebs of nonwoven web 30 into the nip between the combining rolls 124. Atracking system manufactured by the Fife Corporation of Oklahoma City,Okla., and sold as Model Op6 LRA may be suitable.

The nip between the combining rolls 124 compresses the nonwoven web 30into superposing contacting relationship with the elastomeric adhesivebacking 34, causing the pressure sensitive adhesive backing 34 to bondto the nonwoven web 30, joining the two materials to form the femalefastening component 22. As used herein, the term "superpose" or"superposing" will refer to one layer of material having a particulargeometric shape being laid upon another layer of material having asubstantially similar geometric shape such that all like parts of thetwo layers of material substantially coincide.

The combining rolls 124 may take on any number of differentconfigurations, as are known in the art. For example, the combiningrolls 124 may have smooth surfaces or may have grooves, teeth or anypatterns of indentations and/or raised areas on their surfaces. Further,the combining rolls 124 may be identical or may have different surfacecharacteristics, as described above.

Once the nonwoven web 30 and the elastomeric adhesive backing 34 havebeen joined to form the female fastening component 22, the laminate 90is returned to a relaxed condition. In this configuration, the nonwovenweb 30 will become gathered in at least the direction parallel to thepath of response of the adhesive film 34, which will form ridges,wrinkles, or furrows extending outwardly from the first surface 31 ofthe female component 22 capable of entangling the hooks 28 of acomplementary male fastening component 24. The elastomeric laminate 90will be elastically extensible in the direction parallel to the path ofresponse of the adhesive film 34 up to about the free length of thenonwoven web 30.

Contracting the laminate 90 to a relaxed condition can be accomplishedin a number of ways, including simply removing the laminate 90 from thetentering belts 135 and allowing it to contract. More preferably,however, as shown in FIG. 13, the laminate 90 can remain adhered to thebelts 140 and 142 as they travel from the diverging end 144 towards theconverging end 146 of their cycle. As the belts 140 and 142 travel fromthe diverging end 144 toward the converging end 146, the belts 140 and142 converge, and thus contract the laminate 90. (As used herein, theterms "converge" and "converging" mean to move closer together.)Alternatively, as shown in FIG. 11, the laminate 90 may be removed fromthe belts 140 and 142 and transported to a separate configuration ofconverging belts 158. Although the converging belts 158 may take on anumber of different configurations, a detailed description of onepreferred embodiment of the converging belts is described in theco-pending U.S. application Ser. No. 08/254,812, entitled "Apparatus ForContinuously Stretching or Continuously Releasing Stretching Forces FromA Web Using Two Pairs of Opposing Non-Planar Belts", filed on Jun. 6,1994, in the names of L. John Viltro, et al. which is incorporatedherein by reference.

After the laminate 90 is contracted, it is removed from either thetentering belts 135 or the converging belts 158, leaving exposed thepressure sensitive adhesive of the second surface 33 of the adhesivebacking 34. The exposed surface may be used to bond the female fasteningcomponent 22 to an absorbent article or any other desired article, ormay be deactivated by blocking as is commonly known in the art so thatthe adhesive of the elastomeric adhesive backing 34 does not bond toother materials through the pressure sensitive properties of theelastomeric adhesive backing 34. Blocking is accomplished by an adhesivedeactivation system (not shown) applying a powder of resin to theexposed face of the elastomeric adhesive backing 34. Suitable resinpowders include talcum powder, polyolefinic powders, and preferably aresin similar to that used for the nonwoven web 30. Alternatively, theexposed face of the elastomeric adhesive backing 34 may be deactivatedby applying a non-adhesive elastomeric film, nonwoven, foam or any othersuitable non-adhesive material thereto. An example of one suitablenon-adhesive elastomeric film is H2901 manufactured by Findley AdhesivesCorporation of Wauwatosa, Wis.

Alternative Embodiments

One preferred alternative embodiment of the present invention forproviding regions of differential stretch throughout the adhesive film34, as shown in FIG. 11, comprises three tentering belts, a first belt140a, a second belt 142a, and a third belt 143a. (As used herein, theterm "differential stretch" refers to areas of the adhesive film 34 thathave been unequally elongated.) As discussed above, spaced apart regionsof the second surface 33 of the adhesive 34 are adhered to each of thetentering belts. In this particular embodiment, a first region 159a ofthe adhesive film 34 is adhered to the first belt 140a, a second region160a of the adhesive film 34 is adhered to the second belt 142a and athird region 161a of the adhesive film is adhered to the third belt143a. As the belts move in the machine direction, the first belt 140aand the second belt 142a diverge at a rate different from the rate atwhich the second belt 142a and the third belt 143a diverge, thusproducing two regions of differential stretch in the adhesive film 34.

Another preferred alternative embodiment, as shown in FIG. 12, comprisesa first pair 180 of tentering belts comprises belts 182 and 184, and asecond pair 185 of tentering belts comprises belts 187 and 189. Each ofsaid belts contacts a different spaced apart region of the secondsurface 33 of the adhesive film 34. As the pairs of belts move in themachine direction, they diverge at different rates producing areas ofdifferential stretch throughout the adhesive film 34. (Of course, thefirst pair 180 could comprise tentering belts 184 and 187 and the secondpair 185 could comprise the tentering belts 182 and 189.) Further,numerous other configurations are contemplated wherein some of thetentering belts diverge and others run parallel to each other, thusproducing an adhesive film 34 having portions that are stretched betweenthe diverging belts and other portions that are left unstretched betweenthe parallel belts. (Although some preferred embodiments have beendiscussed, it should be noted that any number of tentering belts may beused to produce any combination of stretched and relaxed regionsthroughout the adhesive film 34.)

Yet another alternative embodiment of the present invention provides afemale fastening component 22 with multi-directional stretch. In thisembodiment, the adhesive film 34 may be drawn through the nip formedbetween a pair of tensioning rolls (not shown). The tensioning rollsprovide for machine direction stretching the adhesive film 34 prior tobeing applied to the tentering belts 135, this provides a laminate whichis elastically extensible in two directions, i.e., the machine directionand the cross machine direction. A laminate which is elasticallyextensible in the machine direction and methods of forming such alaminate are described in greater detail in U.S. Pat. No. 5,032,120,entitled "Disposable Absorbent Article Having Improved Leg Cuffs",issued Jul. 16, 1991, to Mary E. Freeland and Patrick J. Allen, which isincorporated herein by reference.

Method of Making a Tri-laminate Embodiment

The above-described method of producing a female fastening componentcomprising a single nonwoven web 30 joined to the first surface 31 ofthe elastomeric adhesive film 34 can also be used to produce atri-laminate female fastening component comprising a nonwoven web 30,joined to the first surface 31 of the backing 34 and a second lamina 80joined to the second surface 33 of the backing 34. As described above,the nonwoven web 30 and the backing 34 are joined to form the laminate90. However, when the laminate 90 exits the nip between combining rolls124, the exposed face of the adhesive backing 34 is not deactivated asdescribed above. Rather, as shown in FIG. 14, the laminate 90 is allowedto remain on the tentering belts 135 as the tentering belts 135 movefrom the diverging end 144 of their cycle toward the converging end 146of their cycle. Alternatively, as is shown in FIG. 15, the laminate 90may be transported to the separate converging belts 158. In either case,the laminate 90 may be partially or fully relaxed prior to applicationof a second lamina 80.

The second lamina 80 is provided by the additional process module 113,as is shown in FIGS. 14 and 15. The second lamina 80 is taken from theunwind roll 150 and preferably passes through the S-wrap tensioning roll152 to provide for proper tensioning and prevent puckering or bunchingof the lamina 80. Guide roll 156 guides the second lamina 80 into thecombining rolls 162. If necessary, a tracking system, not shown, as iscommonly utilized and known in the art, may be employed in the processmodule 113 to optimally track and adjust the second lamina 80 into thecombining rolls 162.

After the laminate 90 comprising the nonwoven 30 and the elastomericadhesive backing 34 exits the converging belts 158, the second surface33 of the adhesive backing 34 is brought into contact with the secondlamina 80. The laminate 90 and the second lamina 80 are passed throughthe nip of combining rolls 162 under sufficient pressure for theadhesive 34 to adhere to the lamina 80, thus forming the tri-laminatefemale fastening component 100.

In a preferred embodiment, the second lamina 80 is joined to theadhesive backing 34 after the laminate 90 has been at least partially,yet not fully relaxed. (This creates a tri-laminate with thecharacteristics and benefits described above with respect to onealternative embodiment of the present invention as shown in FIG. 6.)Preferably, the second lamina 80 is joined to the adhesive backing 34after the laminate 90 has been relaxed such that the lateral dimensionsof the laminate 90, after converging, is between about 90% and about 50%of the lateral dimensions of the lamina 22 when fully stretched. In anespecially preferred embodiment, the second lamina 80 is joined to theadhesive backing 34 after the laminate 90 has been relaxed such that thelateral dimensions of the laminate 90, after converging, is about 70% ofthe lateral dimensions of the laminate 90 when fully stretched. However,embodiments are contemplated wherein the second lamina 80 is joinedafter the laminate 90 is completely relaxed, or while the laminate 90 isfully stretched.

After the tri-laminate 100 has been formed, as described above, thetri-laminate 100 may be adhered to an absorbent article or any otherdesired object. The process of forming the tri-laminate 100 leavesexposed the portions of the second surface 33 that were adhered to thetentering belts 35. Thus, the portions of the second surface 33 of theadhesive film that were adhered to the tentering belts 35 can be used tojoin the tri-laminate 100 to any desired object without the use of anyadditional adhesive.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A female component of a refastenable fasteningdevice capable of engaging a complementary hook fastening component,said female component comprising:an elastomeric adhesive backing havingan elongated orientation, a relaxed orientation, and a path of responsealong which said material contracts from said elongated orientation tosaid relaxed orientation; and a nonwoven web in contact with, andthereby secured to, said elastomeric adhesive backing, said nonwoven webbeing secured to said elastomeric adhesive backing while said backing isin said elongated orientation, said nonwoven web comprising amultiplicity of fibrous elements comprising filaments that are joinedtogether with inter-fiber bonds at spaced, fixed regions along thelength of each of said filaments to define between each pair of fixedregions an unsecured catching region, wherein said fibrous elementscomprise those filaments that are shirred when said backing contracts tosaid relaxed orientation.
 2. The female fastening component of claim 1wherein said filaments are positioned on said backing essentiallyperpendicular to said path of response of said elastomeric adhesivebacking.
 3. The female fastening component of claim 1 wherein saidfilaments are randomly positioned on said elastomeric adhesive backing.4. The female fastening component of claim 1 wherein said nonwoven webcomprises carded polypropylene filaments.
 5. The female fasteningcomponent of claim 1 wherein said inter-fiber bonds are arranged in adiamond-shaped pattern.
 6. A disposable absorbent article comprising aliquid pervious topsheet, a liquid impervious backsheet joined with saidtopsheet, an absorbent core positioned between said topsheet and saidbacksheet, and a fastening system for fastening said disposableabsorbent article about a wearer, wherein said fastening systemcomprises the female fastening component of claim
 1. 7. The disposableabsorbent article of claim 6 further comprising a waistband, whereinsaid waistband comprises said female fastening component.